JP2005053101A - Form for molding porous ceramic and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To bake a ceramic molded product having an upper flat surface and always having a definite thickness. <P>SOLUTION: This molding form is constituted so that a lid 4 is provided to the upper surface of an upwardly opened casing 1 in a freely liftable manner and raised along with the expansion of a material C to be molded to guide the side part 4a of the lid 4 along the guide 2 provided to the casing 1. Since a stopper 3 is provided to the casing 1 to stop the rising of the lid 4, the expansion of the material C to be molded is suppressed to form the upper flat surface of the molded product. If the stopper 3 is provided to the casing 1 in a liftable manner so as to be fixed at a predetermined height position, allowable expansion quantity can be adjusted. If excitation and pressure are applied to the material C to be molded using this molding form, a flatter upper surface is provided, homogenous filling can be performed and a degree of expansion is made equal. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a forming mold for a porous ceramic molded body formed using slag and a method for producing the same.

  Porous ceramic molded bodies are molded into various shapes such as plate and tube, and by utilizing the porous characteristics, indoor and outdoor water permeable means, filtration means, moisture absorption means, sound absorption means, etc. It is used for multiple purposes (see, for example, Patent Document 1).

  As a manufacturing method of such a molded body, for example, a manufacturing method using foamable slag as a raw material is common. In this manufacturing method, a forming mold is filled with foamable slag made of water-cooled slag, foaming material, or the like, and a molding material such as a core material, and the forming mold is put into a heat treatment furnace to foam and fire the molded body. (See, for example, Patent Document 2).

In the course of this heat treatment, since the volume of the material to be molded expands with foaming due to the heat treatment, for example, a casing 10 having an open top as shown in FIG. 5 is used as the molding frame. Since the molding material C expands to the upper surface side by performing heat treatment using the casing 10 while the upper surface is opened and foaming, firing, etc. of the molding material C, residual internal stress on the molded body is left. Less. For this reason, it is possible to prevent excessive stress from being applied to the core material constituting the molded body, and to prevent a large distortion from occurring in the molded body by releasing a part of the residual stress after demolding. (For example, refer to Patent Document 3).
JP 2002-247915 A JP 2002-145679 A Japanese Patent No. 2911887 (page 5, Fig. 1-2)

  In the production of a porous ceramic molded body using a conventional mold, as shown in FIG. 5 (a), the casing 10 was put into a heat treatment furnace with the upper surface open. As shown in FIG. 5 (b), the molded article upper surface center part, which is difficult to be restrained by the mold frame, tends to expand larger than its end part, as shown in FIG. For this reason, the thickness of the molded body is often non-uniform. Moreover, since the filling density of the raw material into the molding frame is not necessarily uniform for each solid of the molded body, the amount of expansion may differ for each solid.

  For this reason, in order to make the upper surface a flat surface without unevenness and to make each molded product have a certain thickness, the finished molded product shown in FIG. It was necessary to take molding measures such as cutting as indicated by a chain line.

  However, the re-molding of the molded body by cutting or the like scrapes off the foamed portion B shown in FIG. 5, so that the foamed portion B is exposed on the upper surface of the molded body that becomes the cutting surface, thereby forming irregularities. . When a molded body is used for each application, if the foreign matter hits the unevenness, the surface may be peeled off, so that molding by cutting may not be preferable.

  Accordingly, an object of the present invention is to fire a molded body having a flat upper surface and always having a constant thickness.

  In order to solve the above-mentioned problems, the present invention fills a molding material comprising a slag, a foam material, and a core material, puts the molding mold into a heat treatment furnace, and foams the slag to form a porous ceramic. The mold is used for molding a casing, and a lid for closing the opening is provided on the upper surface of the casing at the upper surface opening through a guide provided on the casing, and the lid is fixed to the casing. A stopper that stops at a degree of ascent and descent is provided, and the thickness of the porous ceramic molded body is set by the stopper.

  In this way, the lift of the lid is forcibly stopped at a certain position to prevent the molded body from expanding further upward, so that the expansion of the central portion of the molded body is released to the end, and there is no unevenness. A flat top surface can be formed.

  In addition, if the position where the lid stops is set to a height corresponding to the degree of expansion of the molding material, it is possible to prevent excessive internal stress from being applied to the core material and the molded body itself, and a constant thickness is always maintained. It can be a molded body.

  It is possible to adopt a configuration in which the stopper is provided on the casing so as to be movable up and down and can be fixed at a predetermined lift position so that the contact position with the lid can be adjusted in the vertical direction. In this way, since the amount of expansion allowed for the molding can be adjusted using the same mold, it is possible to finish various molded body thicknesses according to various predetermined dimensions. .

  In this method for producing a molded body using the mold, vibration and / or pressure are applied to the material to be molded filled in the mold. For example, the degree of expansion of the molding material at the time of foaming and firing can be made equal if the lid on the molding material is vibrated in advance before heat treatment so that the molding material is uniformly filled into the casing.

  In addition, the molding mold is filled with a molding object, a lid is placed thereon, the inside of the casing is closed, and in this state, the stopper is lowered to lower the lid toward the molding material. Try to press. In this way, it is possible to press the material to be molded before heat treatment using only the lid and stopper attached to the casing without using a pressurizing device or the like. The pressure process is simplified. Of course, the material to be molded may be pressurized by applying a downward load to the upper surface of the lid by means other than the stopper, for example, by placing a weight. These pressurizations have the effect of smoothing the surface of the molded body after the heat treatment. In addition, this pressurization and the said vibration measures can also be used together as needed.

  Since this invention was carried out as described above, a molded article having a flat upper surface and always having a constant thickness can be fired.

  An embodiment is shown in FIG. 1 to FIG. 3, and a forming mold of this embodiment is filled with a material to be molded such as a water-cooled slag or a foamed slag as a raw material and a core material. The molding mold is put into a heat treatment furnace and heat-treated, thereby foaming the material to be molded and firing it into a molded body.

  As shown in FIG. 1, the forming mold is composed of a casing 1 opened on the upper surface and a lid 4 placed on the molding material C filled in the casing 1 so as to close the opening. The casing 1 has a rectangular parallelepiped internal space that is the shape of the molded body to be sought, and among the four side walls constituting the internal space, the other opposing ones that extend upward from the opposing side wall upper edges 5 are provided. The upper edge of the side wall is provided with a flange 6 protruding so as to face the inside.

  The lid 4 is provided so as to be movable up and down with respect to the casing 1 so as to rise with expansion due to foaming of the molding material C by placing it on the molding material C such as the water-cooled slag filled in the casing 1. The raising and lowering of the lid 4 is guided in the vertical direction through the guide 2 when the side walls 4 a of the lid 4 abut against the guide 2 with the four side walls of the casing 1 as the guide 2.

  As shown in FIG. 1, the flange portion 6 of the casing 1 is provided with a stopper 3 formed by screwing a bolt upward from the lower surface of the flange portion 6, and the lid 4 has a lower end 3 a of the stopper 3. The lid 4 is prevented from rising.

  By adjusting the screwing depth of the bolt as the stopper 3, the height of the lower end 3a is changed, so that the contact position between the lower end 3a and the upper surface of the lid 4 can be adjusted to a desired position in the vertical direction. For this reason, while adjusting the degree of expansion of the molded body to the upper surface side, the upper surface of the molded body is always in contact with the lower surface of the lid 4 at least in the process of finishing. Can be formed.

  At this time, the stopper 3 may be screwed upward so that the bolt head comes downward with respect to the flange 6 as shown in FIG. 1, or as shown in FIGS. Further, the bolt head may be screwed downward so that the bolt head comes upward with respect to the flange portion 6.

  Further, by providing the lid 4 that can be moved up and down in the molding frame for manufacturing the molded body in this way, the material C filled in the molding frame is vibrated and pressurized before the heat treatment. It becomes easy to perform.

  That is, by applying vibration to the lid 4 on the molding material C in advance using a vibrator such as a vibrator on the lid 4 before heat treatment, the molding material C filled in the casing 1 is obtained. Then, it is consolidated in the casing 1 and approaches homogeneous. By making the filling of the molding material C close to homogeneity, the degree of expansion of the molding material C during foaming and firing can be made equal for each molded body and for each part of the molded body.

  Further, the lid 4 is pressed downward toward the molding material C by lowering the fixing position of the stopper 3 while the molding material C is filled in the casing 1. If it does in this way, pressurization with respect to the molding material C before heat processing can be easily performed using the lid | cover 4 and the stopper 3. FIG.

  In addition, it is necessary to set the height of the collar portion 6 or the bolt length of the stopper 3 so that the lower end 3a of the stopper 3 can be screwed to a position positioned below the upper edge 5 of the side wall. . That is, since the molding material C before heat treatment (before expansion) is filled so that the upper surface is below the side wall upper edge 5 shown in FIG. 1, in order to apply pressure to the molding material C This is because the lid 4 needs to be pressed at a position below the upper edges 5 on both side walls.

  In this embodiment, the stopper 3 is provided with the flange 6 on the upper edge of the opposite side wall of the casing 1 and screwed into the flange 6, but is not limited to this embodiment. For example, another embodiment is shown in FIG.

  This molding frame is provided with the L-shaped stopper 3 on the upper edge 5 so that it can be moved up and down without providing the flange portion 6 on the upper edge of the two opposite side walls of the casing 1. The L-shaped stopper 3 has a vertical portion 3v that is fixed along the outside of the side wall of the casing 1, and a horizontal portion 3f that protrudes from the upper end of the vertical portion toward the casing 1 side.

  The vertical portion 3v is provided with an elongated hole 3b in the vertical direction, and a fixing bolt 3c is screwed into the side wall of the casing 1 through the elongated hole 3b. In a state in which the fixing bolt 3c is not tightened, the L-shaped stopper 3 can be moved up and down to the casing 1 through the elongated hole 3b. By tightening the fixing bolt 3c at an appropriate lifting position, the vertical portion is placed on the side wall of the casing 1. It is pressed and fixed so as not to move up and down.

  After the lid 4 is placed on the molding material C filled in the casing 1, the L-shaped stopper 3 is attached by the fixing bolt 3c. The L-shaped stopper 3 is fixed to an appropriate height, and a bolt 3d is screwed downward into the screw hole of the horizontal portion 3f from the upper surface. The molding material C expands with the heat treatment, the lid 4 rises, and comes into contact with the lower end 3e of the bolt 3d, so that the rise of the lid 4 can be stopped.

  Further, the height of the lid 4 can be changed by adjusting the screwing degree of the bolt 3d, and the L-type stopper 3 can also be raised and lowered, so that the adjustment range of the height of the lid 4 is wide and versatile. Can be a high formwork. Further, since the L-shaped stopper 3 can be detached, it is easy to remove the finished molded body.

  The number of the L-shaped stoppers 3 is arbitrary, but in order to make the upper surface of the molded body flat, it is necessary to be provided on at least two opposing side walls.

  In addition, when the function of adjusting the fixed height of the stopper 3 is not required, it may be fixed to the casing 1 instead of the stopper 3 of this embodiment, for example, as shown in FIG. In addition, the lid 4 may be fitted into a horizontal groove provided on the side wall of the casing 1 so that the lid 4 is fixed in the height direction so that it does not move up and down.

  Note that the mold used in this embodiment is preferably made of ceramic or non-metal in order to reduce the influence on the molded product due to thermal expansion of the mold itself. Further, when removing the molded body from the mold, it is desirable to provide a minute taper on the side wall of the casing 1 that becomes wider as it goes upward.

Perspective view of one embodiment Front view of FIG. FIG. 3 is a cross-sectional view of the same embodiment when the molded body is fired, in which (a) is a schematic view showing before heat treatment and (b) is after heat treatment. Perspective view of another embodiment It is sectional drawing at the time of baking of the molded object of a prior art example, (a) is before heat processing, (b) is a schematic diagram which shows after heat processing

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,10 Casing 2 Guide 3 Stopper 3a Lower end 3b Long hole 3c Fixing bolt 3d Bolt 3e Lower end 3f Horizontal part 3v Vertical part 4 Lid 4a Side part 5 Upper edge 6 Side wall B Blow part C Molding material

Claims (3)

The molding material C composed of slag, foam material and core material is filled into a molding die, and the molding die is put into a heat treatment furnace, and the slag is foamed to form a porous ceramic. The mold,
A lid 4 that closes the opening is provided on the upper surface of the casing 1 that is open on the top surface so as to be movable up and down via a guide 2 provided on the casing 1, and a stopper 3 that stops the lid 4 at a certain degree of elevation is provided on the casing 1. Then, a molding die characterized in that the thickness of the porous ceramic is set by the stopper 3.   The molding die according to claim 1, wherein the stopper 3 is provided on the casing 1 so as to be movable up and down, and can be fixed at a predetermined lifting position.   It is a manufacturing method of the porous ceramic molded object which uses the shaping | molding die of Claim 1 or 2, Comprising: With respect to the to-be-molded material C with which the said shaping | molding mold was filled, vibration and pressurization, or any of them were carried out. The manufacturing method of the molded object characterized by performing.

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